Flat-bottom stand-up bag, vertical form, fill, and seal system and methodology for utilizing the same

ABSTRACT

A vertical form fill and seal system supports a sheet of material having material segments and a tube sized for drawing edges of the elongated sheet of material together in an overlapping configuration to form the sheet into a substantially tube shape. The VFFS also includes a sealer that seals the edges of the material to one another and a gusseting mechanism sized for forming a gusseted tuck in each of a left panel portion of the material and a right panel portion of the material. A cutting mechanism removes a first portion and a second portion of a first segment of the material segments in order to form a first cut and a second cut in the first segment and a sealing mechanism folds and seals the first segment at the first cut and at the second cut to provide an end wall with a substantially flat, rectangular-shaped footprint.

CROSS REFERENCE TO RELATED APPLICATION

This application claims the benefit of U.S. Provisional application No.62/134,877, filed on Mar. 18, 2015. The entire contents of theaforementioned application are hereby incorporated by reference in theirentirety.

TECHNICAL FIELD

This disclosure relates to a flat-bottom stand-up bag, a vertical form,fill, and seal (VFFS) system and a methodology for utilizing the same.

BACKGROUND

Flat-bottom stand-up bags typically contain deposited materials such as,for example, foodstuff (e.g., cereal, chips, popcorn, candy, nuts, orthe like). Known flat-bottom stand-up bags include several designdeficiencies that may result in, for example, an undesirable entrapmentof the deposited material between folds of the material defining thebag, which may contribute to an imbalance of the bag. Such imbalances ofthe bag may result in the bag not being arranged in an uprightorientation, thereby requiring an external structure such as a box orother fixture to ensure that the bag remains properly orientated on adisplay shelf. Without support from such an external structure, the bagmay be susceptible to tipping over which, in turn, prevents a consumerfrom easily identifying the contents of the bag. While such externalstructures adequately support a bag on a display shelf, such structuresadd to the overall cost and complexity associated with packaging anddisplaying foodstuff.

SUMMARY

A vertical form fill and seal system is provided and includes a spindlethat rotatably supports an elongated sheet of material defined by aplurality of material segments, whereby each of the plurality ofmaterial segments includes a first aperture and a second aperture formedthrough the sheet of material. The system additionally includes aforming tube sized for drawing a left edge and a right edge of theelongated sheet of material together in an overlapping configuration toform the elongated sheet of material into a substantially tube shape anda sealer sized for sealing the left edge and the right edge of theelongated sheet of material to one another to form a longitudinal seal.A gusseting mechanism is also provided and is sized for forming agusseted tuck in each of a left sidewall panel portion of thesubstantially tube-shaped elongated sheet of material and a rightsidewall panel portion of the substantially tube-shaped elongated sheetof material. A sealing mechanism folds and seals a first segment of theplurality of material segments at the first aperture and at the secondaperture to provide an end wall of the first segment with asubstantially flat, rectangular-shaped footprint.

In one configuration, the system additionally includes a cuttingmechanism that severs the first segment from a second segment locateddownstream from the first segment. The cutting mechanism severs thefirst segment at an opposite end of the first segment than the end wallfollowing formation of the end wall to sever the first segment from athird segment located upstream from the first segment.

In one configuration, the cutting mechanism and the sealing mechanismform an integrated machine. The integrated machine may include asubstantially “K” shape.

In one configuration, the cutting mechanism and the sealing mechanismcooperate to provide a sealed edge at the end wall that has a pair oflegs extending from a cross member that joins the pair of legs. The legsextend from the cross member at an obtuse angle and away from oneanother.

In one configuration, the cutting mechanism and the sealing mechanismcooperate to provide a sealed edge at the end wall that has asubstantially “U” shape.

In one configuration, the first aperture and the second aperture includea substantially triangular shape, whereby the triangular shape has abase that is substantially coplanar with an outer edge of the firstsegment. Additionally or alternatively, the first aperture is formedthrough the left sidewall portion and the second aperture is formedthrough the right sidewall portion.

In one configuration, the first aperture includes an edge that issubstantially coplanar with an outer edge of the first segment.

In another configuration, a vertical form fill and seal (VFFS) system isprovided and includes a support rod that rotatably supports an elongatedsheet of material defined by a plurality of material segments and aforming tube sized for drawing a left edge and a right edge of theelongated sheet of material together in an overlapping configuration toform the elongated sheet of material into a substantially tube shape.The VFFS also includes a sealer sized for sealing the left edge and theright edge of the elongated sheet of material to one another and agusseting mechanism sized for forming a gusseted tuck in each of a leftsidewall panel portion of the substantially tube-shaped elongated sheetof material and a right sidewall panel portion of the substantiallytube-shaped elongated sheet of material. A cutting mechanism removes afirst portion and a second portion of a first segment of the pluralityof material segments in order to form a first cut and a second cut inthe first segment and a sealing mechanism folds and seals the firstsegment at the first cut and at the second cut to provide an end wall ofthe first segment with a substantially flat, rectangular-shapedfootprint.

In one configuration, a cutter severs the first segment from a secondsegment located downstream from the first segment following formation ofthe end wall of the first segment. The cutter severs the first segmentat an opposite end of the first segment than the end wall followingformation of the end wall to sever the first segment from a thirdsegment located upstream from the first segment

In one configuration, the cutting mechanism is disposed upstream fromthe forming tube. In another configuration, the cutting mechanism isdisposed downstream from the forming tube. Regardless of the location ofthe cutting mechanism, the first portion and the second portion mayinclude a substantially triangular shape.

In one configuration, the cutting mechanism and the sealing mechanismform an integrated machine. The integrated machine may include asubstantially “K” shape.

In one configuration, the cutting mechanism and the sealing mechanismcooperate to provide a sealed edge at the end wall that has a pair oflegs extending from a cross member that joins the pair of legs, the legsextending from the cross member at an obtuse angle and away from oneanother. The cutting mechanism and the sealing mechanism may cooperateto provide a sealed edge at the end wall that has a substantially “U”shape.

In another configuration, a method is provided and includes rotatablysupporting an elongated sheet of material defined by a plurality ofmaterial segments, drawing a left edge and a right edge of the elongatedsheet of material together in an overlapping configuration around aforming tube to form the elongated sheet of material into asubstantially tube shape, and sealing the left edge and the right edgeof the elongated sheet of material to one another. The method alsoincludes forming a gusseted tuck in each of a left sidewall panelportion of the substantially tube-shaped elongated sheet of material anda right sidewall panel portion of the substantially tube-shapedelongated sheet of material and removing by a cutting mechanism a firstportion and a second portion of a first segment of the plurality ofmaterial segments in order to form a first cut and a second cut in thefirst segment. A sealing mechanism folds and seals the first segment atthe first cut and at the second cut to provide an end wall of the firstsegment with a substantially flat, rectangular-shaped footprint.

In one configuration, the method may additionally include severing bythe cutting mechanism the first segment from a second segment locateddownstream from the first segment following formation of the end wall ofthe at first segment. The method may also include severing by thecutting mechanism the first segment at an opposite end of the firstsegment than the end wall following formation of the end wall to severthe first segment from a third segment located upstream from the firstsegment.

In one configuration, removing the first portion and the second portionincludes removing the first portion and the second portion upstream fromthe forming tube. In another configuration, removing the first portionand the second portion includes removing the first portion and thesecond portion downstream from the forming tube.

In one configuration, removing the first portion and the second portionincludes removing a substantially triangular shaped piece of materialfrom the sheet of material.

In one configuration, the folding and sealing provides a sealed edge atthe end wall that has a pair of legs extending from a cross member thatjoins the pair of legs. Providing the sealed edge having the pair oflegs and the cross member includes extending the legs from the crossmember at an obtuse angle and away from one another.

In one configuration, the folding and sealing provides a sealed edge atthe end wall that has a substantially “U” shape.

In another configuration, a bag is provided and includes a frontsidewall panel portion having a first end including a first cross memberextending between and connecting a first edge and a second edge toprovide the first end with a substantially “U” shape. The bag alsoincludes a rear sidewall panel portion having a second end including asecond cross member extending between and connecting a third edge and afourth edge to provide the second end with a substantially “U” shape,whereby the second cross member is attached to the first cross member tocreate a first sealed joint between the front sidewall panel portion andthe rear sidewall panel portion. A right sidewall panel portion extendsbetween and connects the front sidewall panel portion and the rearsidewall panel portion at the first edge and the third edge to create asecond sealed joint at a junction of the right sidewall panel portionand the first edge and a third sealed joint at a junction of the rightsidewall panel portion and the third edge. A left sidewall panel portionextends between and connects the front sidewall panel portion and therear sidewall panel portion at the second edge and the fourth edge tocreate a fourth sealed joint at a junction of the left sidewall panelportion and the second edge and a fifth sealed joint at a junction ofthe left sidewall panel portion and the fourth edge.

In one configuration, the front sidewall panel portion is folded at alocation along a length of the first edge and the second edge to causethe first cross member to oppose a surface of the front sidewall panelportion. The first edge and the second edge may be deformed at the foldto maintain the folded nature of the first edge and the second edge. Inone configuration, the first edge and the second edge receive theapplication of at least one of heat and pressure at the fold to maintainthe folded nature of the first edge and the second edge.

In one configuration, the first edge and the second edge extend from thefirst cross member at an obtuse angle and in opposite directions fromone another. Similarly, the third edge and the fourth edge also extendfrom the second cross member at an obtuse angle and in oppositedirections from one another. In another configuration, the third edgeand the fourth edge extend from the second cross member at an obtuseangle and in opposite directions from one another independent from theconfiguration of the first edge and the second edge.

In one configuration, the second sealed joint and the third sealed jointterminate at the first sealed joint. Similarly, the fourth sealed jointand the fifth sealed joint terminate at the first sealed joint. In sodoing, the first sealed joint cooperates with the second sealed jointand the fourth sealed joint to provide the first end with a continuous,sealed joint extending along the first edge, the second edge, and thefirst cross member. Likewise, the first sealed joint cooperates with thethird sealed joint and the fifth sealed joint to provide the second endwith a continuous, sealed joint extending along the third edge, thefourth edge, and the second cross member.

The details of one or more implementations of the disclosure are setforth in the accompanying drawings and the description below. Otheraspects, features, and advantages will be apparent from the descriptionand drawings, and from the claims.

DESCRIPTION OF DRAWINGS

FIG. 1A is a perspective view of an exemplary vertical form, fill andseal (VFFS) system.

FIG. 1B is a perspective view of an exemplary finishing station of theVFFS system of FIG. 1A.

FIG. 1C a perspective view of an exemplary finishing station of the VFFSsystem of FIG. 1A.

FIG. 2 is a top view of an exemplary elongated sheet of materialincluding a plurality of segments each defining a unit of material thatwill form an exemplary flat-bottom stand-up bag.

FIG. 3 is a top view of a segment of the elongated sheet of material ofFIG. 2 that will form an exemplary flat-bottom stand-up bag.

FIG. 4A is a perspective view of a portion of a finishing station of theVFFS system of FIG. 1A and a portion of a segment of the elongated sheetof material of FIG. 3 that is formed by the VFFS to be in asubstantially cylindrical or tube shape.

FIG. 4B is another perspective view of the portion of a finishingstation of the VFFS system of FIG. 4A and the portion of the segment ofthe elongated sheet of material of FIG. 4A.

FIG. 4C is a perspective view of the segment of the elongated sheet ofmaterial of FIG. 4B.

FIG. 5A is a perspective view of a portion of a finishing station of theVFFS system of FIG. 1A and the portion of the segment of the elongatedsheet of material of FIG. 4C.

FIG. 5B is a perspective view of the portion of a finishing station ofthe VFFS system of FIG. 5A and the portion of the segment of theelongated sheet of material of FIG. 5A.

FIG. 6 is a perspective view of a portion of a finishing station of theVFFS system of FIG. 1A and the portion of the segment of the elongatedsheet of material of FIG. 5B.

FIG. 7 is a perspective view of a portion of the VFFS system of FIG. 1Aand the portion of the segment of the elongated sheet of material ofFIG. 6.

FIG. 8A is a perspective view of a portion of the finishing station ofthe VFFS system of FIG. 6 and the portion of the segment of theelongated sheet of material of FIG. 7.

FIG. 8B is another perspective view of the portion of the finishingstation of the VFFS system of FIG. 8A and the portion of the segment ofthe elongated sheet of material of FIG. 8A.

FIG. 8C is another perspective view of the portion of the finishingstation of the VFFS system of FIG. 8A and the portion of the segment ofthe elongated sheet of material of FIG. 8A.

FIG. 8D is a bottom view of the portion of the segment of the elongatedsheet of material of FIG. 8A.

FIG. 9A is a perspective view of an exemplary VFFS system.

FIG. 9B is a perspective view of an exemplary finishing station of theVFFS system of FIG. 9A.

FIG. 9C is a perspective view of an exemplary finishing station of theVFFS system of FIG. 9A.

FIG. 9D is a perspective view of an exemplary finishing station of theVFFS system of FIG. 9A.

FIG. 9E is a perspective view of an exemplary finishing station of theVFFS system of FIG. 9A.

FIG. 10A is a perspective view of a portion of a finishing station ofthe VFFS system of FIG. 9A and a portion of a segment of the elongatedsheet of material of FIG. 3 that is formed by the VFFS to be in asubstantially cylindrical or tube shape.

FIG. 10B is another view of the portion of a finishing station of theVFFS system of FIG. 10A and the portion of the segment of the elongatedsheet of material of FIG. 10A.

FIG. 10C is a perspective view of the segment of the elongated sheet ofmaterial of FIG. 10B.

FIG. 11 is a perspective view of a portion of a finishing station of theVFFS system of FIG. 9A and the portion of the segment of the elongatedsheet of material of FIG. 10C.

FIG. 12 is a perspective view of a portion of the VFFS system of FIG. 9Aand the portion of the segment of the elongated sheet of material ofFIG. 11.

FIG. 13A is a perspective view of a portion of the finishing station ofthe VFFS system of FIG. 11 and the portion of the segment of theelongated sheet of material of FIG. 12.

FIG. 13B is a perspective view of the portion of the finishing stationof the VFFS system of FIG. 13A and the portion of the segment of theelongated sheet of material of FIG. 13A.

FIG. 13C is a perspective view of the portion of the finishing stationof the VFFS system of FIG. 13A and the portion of the segment of theelongated sheet of material of FIG. 13A.

FIG. 13D is a bottom view of the portion of the segment of the elongatedsheet of material of FIG. 13A.

FIG. 14A is a perspective view of an exemplary VFFS system.

FIG. 14B is a perspective view of an exemplary finishing station of theVFFS system of FIG. 14A.

FIG. 14C is a perspective view of an exemplary finishing station of theVFFS system of FIG. 14A.

FIG. 15A is a perspective view of a portion of a finishing station ofthe VFFS system of FIG. 14A and a portion of a segment of the elongatedsheet of material of FIG. 3 that is formed by the VFFS to be in asubstantially cylindrical or tube shape.

FIG. 15B is another perspective view of the portion of a finishingstation of the VFFS system of FIG. 15A and the portion of the segment ofthe elongated sheet of material of FIG. 15A.

FIG. 15C is a perspective view of the segment of the elongated sheet ofmaterial of FIG. 15B.

FIG. 16A is a perspective view of a portion of a finishing station ofthe VFFS system of FIG. 14A and the portion of the segment of theelongated sheet of material of FIG. 15C.

FIG. 16B is a perspective view of the portion of a finishing station ofthe VFFS system of FIG. 16A and the portion of the segment of theelongated sheet of material of FIG. 16A.

FIG. 17 is a perspective view of a portion of a finishing station of theVFFS system of FIG. 14A and the portion of the segment of the elongatedsheet of material of FIG. 16.

FIG. 18 is a perspective view of a portion of the VFFS system of FIG.14A and the portion of the segment of the elongated sheet of material ofFIG. 17.

FIG. 19A is a perspective view of a portion of the finishing station ofthe VFFS system of FIG. 17 and the portion of the segment of theelongated sheet of material of FIG. 18.

FIG. 19B is another perspective view of the portion of the finishingstation of the VFFS system of FIG. 19A and the portion of the segment ofthe elongated sheet of material of FIG. 19A.

FIG. 19C is another perspective view of the portion of the finishingstation of the VFFS system of FIG. 19A and the portion of the segment ofthe elongated sheet of material of FIG. 19A.

FIG. 19D is a bottom view of the portion of the segment of the elongatedsheet of material of FIG. 19A.

FIG. 20 is a flow diagram of an exemplary method for forming aflat-bottom stand-up bag from the elongated sheet of material includingthe plurality of segments of FIG. 2.

FIG. 21 is a flow diagram of another exemplary method for forming aflat-bottom stand-up bag from the elongated sheet of material includingthe plurality of segments of FIG. 2.

FIG. 22 is a flow diagram of yet another exemplary method for forming aflat-bottom stand-up bag from the elongated sheet of material includingthe plurality of segments of FIG. 2.

Like reference symbols in the various drawings indicate like elements.

DETAILED DESCRIPTION

A flat-bottom stand-up bag may be formed from an elongated sheet ofmaterial that is interfaced with a vertical form, fill, and seal (VFFS)system. The VFFS system may be utilized, for example, in the foodproduction industry for depositing foodstuff (e.g., cereal, chips,popcorn, candy, nuts, or the like) into the flat-bottom stand-up bag.The VFFS system includes a finishing station that forms a lower end ofthe flat-bottom stand-up bag and may include at least one of, forexample: (1) a gusseting mechanism for forming gussets along opposingsides of the flat-bottom stand-up bag; (2) a cutting mechanism thatremoves portions of material from the elongated sheet of material thatforms the flat-bottom stand-up bag; and (3) a sealing mechanism thatshapes and seals the lower end of the flat-bottom stand-up bag and anupper end of a subsequent flat-bottom stand-up bag.

Referring to FIG. 1A, in some implementations, a VFFS system 10 includesa plurality of connected components/stations 12-26. The plurality ofconnected components/stations 12-26 include, for example: a support rodor spindle 12; a plurality of tensioners 14; a sheet guide 16; avertically-arranged forming tube 18; a product delivery cylinder 20; apair of spaced-apart drive belts 22; a vertical sealer 24; and afinishing station 26. The VFFS system 10 is shown in simplified form anddoes not illustrate, for example, one or more of: a supporting structureand an enclosure. Therefore, even in the absence of illustrating thesupporting structure and the enclosure, the above described plurality ofconnected components/stations 12-26 of the VFFS system 10 may be said tobe connected to one another due to the fact that the above-describedcomponents 12-26 of the VFFS system 10 are connected to one or more ofthe not-illustrated supporting structure and the enclosure.Alternatively, the plurality of connected components/stations 12-26 ofthe VFFS system 10 may be said to be connected together, or are incommunication with one another upon interfacing an elongated sheet ofmaterial S with the plurality of interconnected components/stations12-26 of the VFFS system 10. The elongated sheet of material S may be,for example, a packaging film, such as: polypropylene; polyester; paper;polyolefin extrusions; adhesive laminates; and other such materials; orfrom layered combinations of the above. If the deposited material isfoodstuff, the elongated sheet of material S may include an innermostmetalized layer that assists in the retention of, for example, flavor ofthe foodstuff.

As seen in FIG. 1A, the elongated sheet of material S is initiallyarranged in the form of a wound roll that is rotatably supported on thesupport rod 12. The wound roll of the elongated sheet of material S isreeled off of the support rod 12 and subsequently interfaced with theremaining plurality of connected components/stations 12-26 of the VFFSsystem 10. As will be described, the VFFS system 10 spatially andphysically manipulates the elongated sheet of material S from a firstorientation in the form of a substantially planar sheet (as seen, forexample, when the elongated sheet of material S is located about theplurality of tensioners 14) to a final orientation in the form of athree-dimensional end product defining a flat-bottom stand-up bag, B.

As seen in, for example, FIGS. 6, 7, and 8A-8D, the flat-bottom stand-upbag B is defined by an enclosed end wall EW having a substantially flat,rectangular-shaped footprint. The substantially flat, rectangular-shapedfootprint assists in maintaining the flat-bottom stand-up bag B in anupright orientation, and, therefore inhibits the flat-bottom stand-upbag B from tipping over once the flat-bottom stand-up bag B is locatedupon a display shelf, for example. Further, the substantially flat,rectangular-shaped footprint also contributes to the formation of theflat-bottom stand-up bag B. In addition, the substantially flat,rectangular-shaped footprint also contributes to having a spatialgeometry that inhibits an undesirable entrapment of the depositedmaterial (e.g., foodstuff) between folds of material defining theflat-bottom stand-up bag B near the enclosed end wall EW of theflat-bottom stand-up bag, B. By preventing the entrapment of thedeposited material between folds of material defining the flat-bottomstand-up bag B near the enclosed end wall, the flat-bottom stand-up bagB is further inhibited from tipping over once the flat-bottom stand-upbag B is located upon a display shelf or other flat surface.

Referring to FIG. 2, an exemplary elongated sheet of material S includesa plurality of segments S_(P) defined by, for example, a first segmentS₁ a second segment S₂ a third segment S₃ and an “n^(th)” segment S_(n)(where n is an integer greater or equal to 1 (n≥1)). Although foursegments (i.e., the first segment S₁ the second segment S₂ the thirdsegment S₃ and the “n^(th)” segment S_(n)) are shown and described atFIG. 2, the elongated sheet of material S is exemplary and not limitedto any particular number of segments. Portions of an exemplary segmentof the plurality of segments S_(P) is described at FIG. 3.

As shown in FIG. 3, all of the material defining each segmentS₁//S₂//S₃//S_(n) is utilized for forming the flat-bottom stand-up bag Bexcept for a first substantially triangular cut section DC₁′ (see also,e.g., FIG. 5B) and a second substantially triangular cut section DC₂′(see also, e.g., FIG. 5B). As shown in FIG. 5B, the first substantiallytriangular cut section DC₁′, and the second substantially triangular cutsection DC₂′, are removed from each segment S₁//S₂//S₃//S_(n) during themanufacture of the flat-bottom stand-up bag B by the VFFS system 10.

With reference to FIG. 3, after forming the first substantiallytriangular cut section DC₁′ and the second substantially triangular cutsection DC₂′ each segment S₁//S₂//S₃//S_(n) is defined by a length L anda width W. The width W is bound by a left edge E_(L) and a right edgeE_(R). The length L is bound by a top edge E_(T) and a bottom edgeE_(B). As a result of the formation of the first cut section DC₁′ andthe second cut section DC₂′ the bottom edge E_(B) is defined by a leftbottom edge portion E_(BL) a middle bottom edge portion E_(BM) and aright bottom edge portion E_(BR).

The length L includes a first length segment L1 a second length segmentL2 and a third length segment L3. The first length segment L1 is boundby the top edge E_(T) and a first horizontal dashed line H₁ that extendsacross the width, W. The second length segment L2 is bound by the firsthorizontal dashed line H₁ and a second horizontal dashed line H₂ thatextends across the width W. The third length segment L3 is bound by thesecond horizontal dashed line H₂ and the bottom edge E_(B).

The first length segment L1 defines a length of a plurality of sidewallpanel portions SP of the flat-bottom stand-up bag B. A plurality ofvertical dashed lines are shown extending across the length L in orderto distinguish the plurality of sidewall panel portions SP of theflat-bottom stand-up bag B from one another. The plurality of sidewallpanel portions SP may include, for example: a front sidewall panelportion SP_(F); a left sidewall panel portion SP_(L); a right sidewallpanel portion SP_(R); a first half of a back sidewall panel portionSP_(B1); and a second half of the back sidewall panel portion SP_(B2).

The second length segment L2 generally defines a length of a pluralityof bottom panel portions BP of the flat-bottom stand-up bag B. Theplurality of dashed lines extending across the length L distinguishesthe plurality of bottom panel portions BP of the flat-bottom stand-upbag B from one another. The plurality of bottom panel portions BP of theflat-bottom stand-up bag B may include, for example: a front bottompanel portion BP_(F); a left bottom panel portion BP_(L); a right bottompanel portion BP_(R); a first half of a back bottom panel portionBP_(B1); and a second half of the back bottom panel portion BP_(B2).

The third length segment L3 generally defines a length of a plurality ofhorizontally sealable lip portions LH of the flat-bottom stand-up bag B.The plurality of horizontally sealable lip portions LH of theflat-bottom stand-up bag B include: a front horizontally sealable lipportion LH_(F); a first half of a back horizontally sealable lip portionLH_(B1); and a second half of the back horizontally sealable lip portionLH_(B2).

All of the length L and a first portion W₁ of the width W extending fromthe left edge E_(L) forms a first half a vertically-sealable lip portionLV₁. All of the length L and a second portion W₂ of the width Wextending from the right edge E_(R) forms a second half of thevertically sealable lip portion LV₂.

Referring back to FIG. 1A, an exemplary method (see also, e.g., 100 atFIG. 20) for utilizing the VFFS system 10 is described. In someimplementations, the steps 101-106 of the method 100 are sequentiallycarried out in a successive order.

An elongated sheet of material S is rotatably supported at 101 on thesupport rod 12 and is arranged about the plurality of tensioners 14 inorder to keep the elongated sheet of material S taught as the elongatedsheet of material S is guided through the VFFS system 10. The pluralityof tensioners 14 may be defined by at least, for example, a leadingtensioner 14 ₁ and a trailing tensioner 14 ₇. In some instances, theplurality of tensioners 14 may also include a plurality of intermediatetensioners 14 ₂-14 ₆ arranged between the leading tensioner 14 ₁ and thetrailing tensioner 14 ₇. The elongated sheet of material S is passedfrom the trailing tensioner 14 ₇ for subsequent guiding over the sheetguide 16 and toward the vertically arranged forming tube 18 and theproduct delivery cylinder 20. As shown, there are seven tensioners 14₁-14 ₇, however, any number of tensioners 14 ₁-14 ₇ may be used.

The sheet guide 16 directs the elongated sheet of material S into thevertically arranged forming tube 18 that is arranged around the productdelivery cylinder 20. Once the elongated sheet of material S is directedinto the vertically-arranged forming tube 18, the vertically-arrangedforming tube 18 draws the left edge E_(L) and the right edge E_(R) ofthe elongated sheet of material S together in an overlappingconfiguration at 102 while also reconfiguring the spatial geometry ofthe elongated sheet of material S from a substantially planar shape (asseen, e.g., about the plurality of tensioners 14) to a substantiallycylindrical or tube shape about the vertically-arranged forming tube 18.The pair of spaced-apart drive belts 22 is arranged in direct contactwith the substantially cylindrical or tube-shaped elongated sheet ofmaterial S for advancing the substantially cylindrical or tube-shapedelongated sheet of material S along the vertically arranged forming tube18 and away from a material depositing opening 28 of the productdelivery cylinder 20.

As the substantially cylindrical or tube-shaped elongated sheet ofmaterial S is pulled downwardly by the pair of spaced-apart drive belts22, the overlapping configuration of the left edge E_(L) and the rightedge E_(R) of the elongated sheet of material S results in at least aportion of the first half of the vertically-sealable lip portion, LV₁,to be arranged in an overlapped orientation with respect to at least aportion of the second half of the vertically-sealable lip portion LV₂.Once the first half of the vertically sealable lip portion LV₁ isoverlapped with the second half of the vertically sealable lip portionLV₂ the first half of the vertically sealable lip portion LV₁ is joinedto the second half of the vertically sealable lip portion LV₂ by thevertical sealer 24 at 103.

After the first half of the vertically-sealable lip portion LV₁ isjoined to the second half of the vertically-sealable lip portion LV₂ bythe vertical sealer 24, the substantially cylindrical or tube-shapedelongated sheet of material S is advanced away from the vertical sealer24 by the pair of spaced-apart drive belts 22 and toward the finishingstation 26. Referring to FIGS. 1B and 1C, the finishing station 26 mayinclude one or more mechanisms 26 a, 26 b, and 26 c for furtherspatially and physically manipulating the substantially cylindrical ortube-shaped elongated sheet of material S that will ultimately providethe substantially flat, rectangular-shaped footprint of the flat-bottomstand-up bag B. Some or all of the one or more mechanisms may beconnected to one or more actuators A. The one or more actuators A maycause the one or more mechanisms 26 a, 26 b, 26 c to be spatiallymanipulated relative to the sheet of material S in order to form theflat-bottom stand-up bag B. The one or more actuators A may be connectedto a computing resource C. The computing resource C may send one or moreperiodic actuating signals to the one or more actuators A for causingmovement of or actuating the one or more actuators A.

Referring to FIGS. 1B and 4A-4C, in some implementations, the finishingstation 26 includes a gusseting mechanism 26 a defined by a firststationary gusseting rail 26 a ₁ and a second stationary gusseting rail26 a ₂. The first stationary gusseting rail 26 a ₁ is spaced apart fromthe second stationary gusseting rail 26 a ₂ by a distance D therebyforming a gap G therebetween.

With reference to FIGS. 1B, 4A, and 4B, the drive belts 22 (shown inFIG. 1A) advance the substantially cylindrical or tube-shaped elongatedsheet of material S through the finishing station 26 such that thesubstantially cylindrical or tube-shaped elongated sheet of material Sis drawn through the gap G between the first stationary gusseting rail26 a ₁ and the second stationary gusseting rail 26 a ₂. With referenceto FIGS. 4B-4C, a spacing between the left sidewall panel portion SP_(L)and the right sidewall panel portion SP_(R) of the substantiallycylindrical or tube-shaped elongated sheet of material S is defined by ageometry that is greater than the distance D between the firststationary gusseting rail 26 a ₁ and a second stationary gusseting rail26 a ₂. Accordingly, the pair of stationary gusseting rails 26 a ₁, 26 a₂ cooperate to shape each of the left sidewall panel portion SP_(L) ofthe substantially cylindrical or tube-shaped elongated sheet of materialS and the right sidewall panel portion SP_(R) of the substantiallycylindrical or tube-shaped elongated sheet of material S to include agusseted tuck T at 104 as the drive belts 22 advance the substantiallycylindrical or tube-shaped elongated sheet of material S through thefinishing station 26.

Referring to FIG. 1C, in some instances, the gusseting mechanism 26 amay alternatively include a first gusseting disk 26 a ₁ and a secondgusseting disk 26 a ₂ that are spaced apart by a distance D, therebyforming a gap G therebetween. In some examples, the gusseting disks 26 a₁, 26 a ₂ may be spatially fixed in place. In other examples, eachgusseting disk 26 a ₁, 26 a ₂ may be permitted to rotate about an axisA-A (FIG. 9C) extending through an axial center of each gusseting disk26 a ₁, 26 a ₂. The gusseting disks 26 a ₁, 26 a ₂ may function in asubstantially similar manner as described above with respect to thefirst stationary gusseting rail 26 a ₁ and the second stationarygusseting rail 26 a ₂. If the gusseting disks 26 a ₁, 26 a ₂ arepermitted to rotate about respective axes A-A, the gusseting disks 26 a₁, 26 a ₂ may passively rotate about the respective axes A-A as thespaced-apart drive belts 22 advance the substantially cylindrical ortube-shaped elongated sheet of material S through the finishing station26.

Referring to FIGS. 5A and 5B, in some implementations, the finishingstation 26 further includes a cutting mechanism 26 b. As seen in FIGS.1B and 1C, the cutting mechanism 26 b may include one or a pair ofcutters 26 b ₁, 26 b ₂. The cutter or pair of cutters 26 b ₁, 26 b ₂ mayinclude, but is/are not limited to knives, scissors, punchers,die-cutters, shears, lasers, or the like. After the substantiallycylindrical or tube-shaped elongated sheet of material S has been shapedto form the gusset tucks T as described above, the pair of spaced-apartdrive belts 22 advances the gusseted, substantially cylindrical ortube-shaped elongated sheet of material S through the finishing station26 such that the gusseted, substantially cylindrical or tube-shapedelongated sheet of material S interfaces with the cutting mechanism 26b. The cutting mechanism 26 b removes the first portion DC₁′ and thesecond portion DC₂′ of the gusseted, substantially cylindrical ortube-shaped elongated sheet of material S in order to provide thegusseted, substantially cylindrical or tube-shaped elongated sheet ofmaterial S with a first cut DC₁ and a second cut DC₂ at 105.

Referring to FIG. 6, the finishing station 26 further includes a sealingmechanism 26 c. As seen in FIGS. 1B and 1C, the sealing mechanism 26 cmay include a “K-shaped” sealing mechanism. The “K-shaped” sealingmechanism 26 c provides the bag B with a sealed edge 29 at the end wall(EW) that has a substantially “U” shape. In one configuration, the “U”shape includes two pairs of legs 31 a and 31 b extending from a singlecross member (i.e., sealed lip portion (LH)) 33 that joins the legs 31 aand 31 b. The legs extend from the cross member on both sides of the bagB such that a pair of legs are associated with the front bottom panelportion BP_(F) and a pair of legs are associated with the back bottompanel portion BP_(B1) and the back bottom panel portion BP_(B2).Specifically, a first leg is formed at a sealed junction of the frontbottom panel portion BP_(F) and the left bottom panel portion BP_(L) anda second leg is formed at a sealed junction of the front bottom panelportion BP_(F) and the right bottom panel portion BP_(R). Similarly, athird leg is formed at a sealed junction of the back bottom panelportion BP_(B1) and the left bottom panel portion BP_(L) and a fourthleg is formed at a sealed junction of the back bottom panel portionBP_(B2) and the right bottom panel portion BP_(R).

Each of the legs terminate and are attached to the cross member (i.e.,the sealed lip portion (LH)). Accordingly, when viewing the bag B fromthe front sidewall panel portion SP_(F), the first leg, the second leg,and the cross member cooperate to provide a sealed edge having asubstantially “U” shape. Similarly, when the bag B is viewed from theback sidewall panel portions SP_(B1), SP_(B2), the third leg, the fourthleg, and the cross member cooperate to provide a sealed edge having asubstantially “U” shape. In this configuration, the legs extend from thecross member at an obtuse angle and in a direction away from oneanother. The shape of the sealed edge is generally dictated by the “K”shape of the sealing mechanism 26 c, as shown in FIG. 9B.

Once the bag B is fully formed, the cross member is folded toward thefront bottom panel portion BP_(F) and is held in place by crimping thefirst leg and the second leg, as shown in FIG. 6. The crimp formed inthe first leg and the second leg may be formed by folding the first legand the second leg such that the cross member is brought into closeproximity to the front bottom panel portion BP_(F). Once the crossmember is in the desired position relative to the front bottom panelportion BP_(F), the first leg and the second leg may be locally deformedat the area of the fold via heat and/or pressure to maintain the foldednature of the first leg and the second leg. Folding the first leg andthe second leg in this fashion provides the bag B with a substantiallyflat end wall (EW). While the first leg and the second leg are describedas being folded, the third leg and the fourth leg could alternatively befolded such that the cross member is brought toward the back bottompanel portion BP_(B1) and the back bottom panel portion BP_(B2).

After the gusseted, substantially cylindrical or tube-shaped elongatedsheet of material S has been shaped to include the first cut DC₁ and thesecond cut DC₂, as described above, the pair of spaced-apart drive belts22 advances the cut, gusseted, substantially cylindrical or tube-shapedelongated sheet of material S through the finishing station 26 such thatthe cut, gusseted, substantially cylindrical or tube-shaped elongatedsheet of material S interfaces with the sealing mechanism 26 c. As seenin FIG. 6, the sealing mechanism 26 c may spatially manipulate and sealthe cut and gusseted, substantially cylindrical or tube-shaped elongatedsheet of material S at 106 by: (1) folding the bottom edge E_(B) (see,e.g., FIG. 5B) of the cut and gusseted, substantially cylindrical ortube-shaped elongated sheet of material S such that the fronthorizontally-sealable lip portion LH_(F) overlaps with both of the firsthalf of the back horizontally-sealable lip portion LH_(B1) and thesecond half of the back horizontally-sealable lip portion LH_(B2); andthen (2) sealing the front horizontally-sealable lip portion LH_(F) toboth of the first half of the back horizontally-sealable lip portionLH_(B1) and the second half of the back horizontally-sealable lipportion LH_(B2) to thereby seal the plurality of horizontally-sealablelip portions LH and form the enclosed end wall EW.

Referring to FIG. 7, once the sealing mechanism 26 c of the finishingstation 26 folds and seals the cut and gusseted, substantiallycylindrical or tube-shaped elongated sheet of material S to form theenclosed end wall EW as described above, the VFFS system 10 is thensubsequently actuated for passing foodstuff F (e.g., cereal, chips,popcorn, candy, nuts or the like) through the material depositingopening 28 of the product delivery cylinder 20 and then through thevertically-arranged forming tube 18 for subsequent arrival in a cavityformed by the sealed, folded, cut and gusseted, substantiallycylindrical or tube-shaped elongated sheet of material S. The enclosedend wall EW prevents the foodstuff F from escaping out of the cavity ofthe sealed, folded, cut, gusseted, substantially cylindrical, ortube-shaped elongated sheet of material S while the sealed, folded, cutand gusseted, substantially cylindrical or tube-shaped elongated sheetof material S is still interfaced with the VFFS system 10.

Referring to FIGS. 1A and 8A-8D, the pair of spaced-apart drive belts 22may then advance the sealed, folded, cut and gusseted, substantiallycylindrical or tube-shaped elongated sheet of material S (including thefoodstuff F deposited therein) through the finishing station 26 suchthat the enclosed end wall EW of the sealed, folded, cut and gusseted,substantially cylindrical or tube-shaped elongated sheet of material S(including the foodstuff F deposited therein) is moved past the sealingmechanism 26 c. Movement of the sealed, folded, cut and gusseted,substantially cylindrical or tube-shaped elongated sheet of material S(including the foodstuff F deposited therein), may cease once the topedge ET (as seen in, e.g., FIG. 8A) of the sealed, folded, cut andgusseted, substantially cylindrical or tube-shaped elongated sheet ofmaterial S (including the foodstuff F deposited therein) is arrangedproximate the sealing mechanism 26 c. Then, the sealing mechanism 26 cmay be actuated again for simultaneously sealing the top edge E_(T) ofthe sealed, folded, cut and gusseted, substantially cylindrical or tubeshaped elongated sheet of material S (including the foodstuff Fdeposited therein) while also simultaneously forming an enclosed endwall EW of the next segment of the plurality of segments S_(p) reeledfrom the elongated sheet of material S. When the top edge E_(T) of thesealed, folded, cut and gusseted, substantially cylindrical ortube-shaped elongated sheet of material S (including the foodstuff Fdeposited therein), is sealed as described above, a cutter 27 may severthe sealed, folded, cut and gusseted, substantially cylindrical ortube-shaped elongated sheet of material S (including the foodstuff Fdeposited therein), along the top edge E_(T) to thereby provide the flatbottom stand-up bag B with the foodstuff F provided therein. The cuttermay be incorporated into the sealer 26 c such that the sealer 26 csubstantially simultaneously seals the top edge E_(T) of the bag B andsevers the bag B from the adjacent bag being formed from the sheet ofmaterial S by the VFFS system 10.

Referring to FIG. 9A, an exemplary method (see also, e.g., 200 at FIG.21) for utilizing a VFFS system 10′ is described. In someimplementations, the steps 201-206 of the method are sequentiallycarried out in successive order.

An elongated sheet of material S is rotatably supported on the supportrod 12 at 201 and is arranged about the plurality of tensioners 14 inorder to keep the elongated sheet of material S taught as the elongatedsheet of material S is guided through the VFFS system 10′. The pluralityof tensioners 14 may be defined by at least, for example, a leadingtensioner 14 ₁ and a trailing tensioner 14 ₇. In some instances, theplurality of tensioners 14 may also include a plurality of intermediatetensioners 14 ₂-14 ₆ arranged between the leading tensioner 14 ₁ and thetrailing tensioner 14 ₇. The elongated sheet of material S is passedfrom the trailing tensioner 14 ₇ for subsequent guiding over the sheetguide 16 and toward the vertically arranged forming tube 18 and theproduct delivery cylinder 20.

The sheet guide 16 directs the elongated sheet of material S into thevertically arranged forming tube 18 that is arranged around the productdelivery cylinder 20. Once the elongated sheet of material S is directedinto the vertically-arranged forming tube 18, the vertically-arrangedforming tube 18 draws the left edge E_(L) and the right edge E_(R) ofthe elongated sheet of material S together in an overlappingconfiguration while also reconfiguring the spatial geometry of theelongated sheet of material S from a substantially planar shape (asseen, e.g., about the plurality of tensioners 14) to a substantiallycylindrical or tube shape about the vertically-arranged forming tube 18at 203. The pair of spaced-apart drive belts 22 is arranged in directcontact with the substantially cylindrical or tube-shaped elongatedsheet of material S for advancing the substantially cylindrical ortube-shaped elongated sheet of material S along the vertically arrangedforming tube 18 and away from a material depositing opening 28 of theproduct delivery cylinder 20.

As the substantially cylindrical or tube-shaped elongated sheet ofmaterial S is pulled downwardly by the pair of spaced-apart drive belts22, the overlapping configuration of the left edge E_(L) and the rightedge E_(R) of the elongated sheet of material S results in at least aportion of the first half of the vertically-sealable lip portion LV₁being arranged in an overlapped orientation with respect to at least aportion of the second half of the vertically-sealable lip portion LV₂.Once the first half of the vertically sealable lip portion LV₁ isoverlapped with the second half of the vertically sealable lip portionLV₂, the first half of the vertically sealable lip portion LV₁ is joinedto the second half of the vertically sealable lip portion LV₂ by thevertical sealer 24 at 204.

After the first half of the vertically-sealable lip portion LV₁ isjoined to the second half of the vertically-sealable lip portion LV₂ bythe vertical sealer 24, the substantially cylindrical or tube-shapedelongated sheet of material S is advanced away from the vertical sealer24 by the pair of spaced-apart drive belts 22 and toward the finishingstation 26. Referring to FIGS. 9B-9C and 9D-9E, the finishing station 26may include one or more mechanisms 26 a, 26 b, and 26 c for furtherspatially and physically manipulating the substantially cylindrical ortube-shaped elongated sheet of material S that will ultimately providethe substantially flat, rectangular-shaped footprint of the flat-bottomstand-up bag B. Some or all of the one or more mechanisms may beconnected to one or more actuators A. The one or more actuators A maycause the one or more mechanisms 26 a, 26 b, 26 c to be spatiallymanipulated relative to the sheet of material S in order to form theflat-bottom stand-up bag B. The one or more actuators A may be connectedto a computing resource C. The computing resource C may send one or moreperiodic actuating signals to the one or more actuators A for causingmovement of or actuating the one or more actuators A.

Unlike the VFFS system 10 described above at FIG. 1A, the VFSS system10′ is subtly different in that the finishing station 26 does notinclude the cutting mechanism 26 b arranged proximate to the gussetingmechanism 26 a and the sealing mechanism 26 c. Rather, the cuttingmechanism 26 b (as seen, e.g., at FIG. 9B or 9C) of the VFFS system 10′provides the first cut DC₁ and the second cut DC₂ in the elongated sheetof material S at 202 after the elongated sheet of material S is reeledoff of the support rod 12 and before the elongated sheet of material Sis guided over the sheet guide 16 and toward the vertically-arrangedforming tube 18 and the product delivery cylinder 20 for shaping theelongated sheet of material S into a tube shape. As a result, theelongated sheet of material S is formed to include the first cut DC₁ andthe second cut DC₂ by the cutting mechanism 26 b when the elongatedsheet of material S in the form of a substantially planar sheet (asseen, for example, when the elongated sheet of material S is locatedabout the plurality of tensioners 14) and not when the elongated sheetof material S has been formed into a substantially tube shape andgusseted as described above with respect to the VFFS system 10 of FIG.1A. As seen in FIGS. 9B and 9C, the cutting mechanism 26 b may includeone or a pair of punchers or die-cutters. Alternatively, the cuttingmechanism 26 b may include, but is/are not limited to knives, scissors,shears, lasers, or the like.

Referring to FIGS. 10A-10C, in some implementations, the finishingstation 26 includes a gusseting mechanism 26 a defined by a firststationary gusseting rail 26 a ₁ and a second stationary gusseting rail26 a ₂ defining a pair of stationary gusseting rails 26 a. The firststationary gusseting rail 26 a ₁ is spaced apart from the secondstationary gusseting rail 26 a ₂ by a distance D thereby forming a gap Gtherebetween.

With reference to FIGS. 9B, 10A, and 10B, the pair of spaced-apart drivebelts 22 advances the cut, substantially cylindrical or tube-shapedelongated sheet of material S through the finishing station 26 such thatthe cut, substantially cylindrical or tube-shaped elongated sheet ofmaterial S is drawn through the gap G between the first stationarygusseting rail 26 a ₁ and the second stationary gusseting rail 26 a ₂.With reference to FIGS. 10B-10C, because a spacing between the leftsidewall panel portion SP_(L) and the right sidewall panel portionSP_(R) of the cut, substantially cylindrical or tube-shaped elongatedsheet of material S is defined by a geometry that is greater than thedistance D between the first stationary gusseting rail 26 a ₁ and asecond stationary gusseting rail 26 a ₂, the pair of stationarygusseting rails 26 a ₁, 26 a ₂ shapes each of the left sidewall panelportion SP_(L) of the cut, substantially cylindrical or tube-shapedelongated sheet of material S and the right sidewall panel portionSP_(R) of the cut, substantially cylindrical or tube-shaped elongatedsheet of material S to include a gusseted tuck T at 205 as the pair ofspaced-apart drive belts 22 advances the substantially cylindrical ortube-shaped elongated sheet of material S through the finishing station26.

Referring to FIG. 9C, in some instances, the gusseting mechanism 26 amay alternatively include a first gusseting disk 26 a ₁ and a secondgusseting disk 26 a ₂ that are spaced apart by a distance D therebyforming a gap G therebetween. In some examples, the gusseting disks 26 a₁, 26 a ₂ may be spatially fixed in place. In other examples, eachgusseting disk 26 a ₁, 26 a ₂ may be permitted to rotate about an axisA-A extending through an axial center of each gusseting disk 26 a ₁, 2 b₂. The gusseting disks 26 a ₁, 26 a ₂ may function in a substantiallysimilar manner as described above at FIGS. 10A-10C with respect to thefirst stationary gusseting rail 26 a ₁ and a second stationary gussetingrail 26 a ₂. If the gusseting disks 26 a ₁, 26 a ₂ are permitted torotate about the axis A-A, the gusseting disks 26 a ₁, 26 a ₂ maypassively rotate about the axis A-A as the spaced-apart drive belts 22advance the substantially cylindrical or tube-shaped elongated sheet ofmaterial S through the finishing station 26.

Referring to FIG. 11, the finishing station 26 further includes asealing mechanism 26 c. As seen in FIGS. 9B and 9C, the sealingmechanism 26 c may include a “K-shaped” sealing mechanism.

After the gusseted and cut substantially cylindrical or tube-shapedelongated sheet of material S has been shaped as described above, thedrive belts 22 advance the gusseted and cut substantially cylindrical ortube-shaped elongated sheet of material S through the finishing station26 such that the gusseted and cut substantially cylindrical ortube-shaped elongated sheet of material S is interfaced with the sealingmechanism 26 c. The sealing mechanism 26 c may spatially manipulate andseal the gusseted and cut substantially cylindrical or tube-shapedelongated sheet of material S at 206 in a manner by: (1) folding thebottom edge E_(B) of the gusseted and cut substantially cylindrical ortube-shaped elongated sheet of material S such that the fronthorizontally-sealable lip portion LH_(F) overlaps with both of the firsthalf of the back horizontally-sealable lip portion LH_(B1) and thesecond half of the back horizontally-sealable lip portion LH_(B2) andthen (2) sealing the front horizontally-sealable lip portion LH_(F) toboth of the first half of the back horizontally-sealable lip portionLH_(B1) and the second half of the back horizontally-sealable lipportion LH_(B2) to thereby seal the plurality of horizontally-sealablelip portions LH and form the enclosed end wall EW.

Referring to FIG. 12, once the sealing mechanism 26 c of the finishingstation 26 folds and seals the gusseted and cut substantiallycylindrical or tube-shaped elongated sheet of material S to form theenclosed end wall EW as described above, the VFFS system 10′ is thensubsequently actuated for passing foodstuff F (e.g., cereal, chips,popcorn, candy, nuts or the like) through the material depositingopening 28 of the product delivery cylinder 20 and then through thevertically-arranged forming tube 18 for subsequent arrival in a cavityformed by the sealed, folded, gusseted and cut substantially cylindricalor tube-shaped elongated sheet of material S. The enclosed end wall EWprevents the foodstuff F from escaping out of the cavity of the sealed,folded, gusseted and cut substantially cylindrical or tube-shapedelongated sheet of material S while the sealed, folded, gusseted and cutsubstantially cylindrical or tube-shaped elongated sheet of material Sis still interfaced with the VFFS system 10′.

Referring to FIGS. 9A, 13A, and 13D, the pair of spaced-apart drivebelts 22 may then advance the sealed, folded, gusseted and cutsubstantially cylindrical or tube-shaped elongated sheet of material S(including the foodstuff F deposited therein) through the finishingstation 26 such that the enclosed end wall EW of the sealed, folded,gusseted and cut substantially cylindrical or tube-shaped elongatedsheet of material S (including the foodstuff F deposited therein) ismoved past the sealing mechanism 26 c. Movement of the sealed, folded,gusseted and cut substantially cylindrical or tube-shaped elongatedsheet of material S (including the foodstuff F deposited therein) maycease once the top edge E_(T) of the sealed, folded, gusseted and cutsubstantially cylindrical or tube-shaped elongated sheet of material S(including the foodstuff F deposited therein) is arranged proximate thesealing mechanism 26 c. Then, the sealing mechanism 26 c may be actuatedagain for simultaneously sealing the top edge E_(T) of the sealed,folded, gusseted and cut substantially cylindrical or tube-shapedelongated sheet of material S (including the foodstuff F depositedtherein) while also simultaneously forming an enclosed end wall EW ofthe next segment of the plurality of segments S_(P) reeled from theelongated sheet of material S. When the top edge E_(T) of the sealed,folded, gusseted and cut substantially cylindrical or tube-shapedelongated sheet of material S (including the foodstuff F depositedtherein) is sealed as described above, the sealing mechanism 26 c mayalso include a cutter that severs the sealed, folded, gusseted and cutsubstantially cylindrical or tube-shaped elongated sheet of material S(including the foodstuff F deposited therein), along the top edge E_(T)to thereby provide the flat bottom stand-up bag B with the foodstuff Fprovided therein.

Referring to FIG. 9D, another exemplary implementation of the VFFSsystem 10′ including a gusseting mechanism 26 a defined by a firststationary gusseting rail 26 a ₁ and a second stationary gusseting rail26 a ₂ defining a pair of stationary gusseting rails 26 a is described.The VFFS system 10′ of FIG. 9D is substantially similar to the VFFSsystem 10′ of FIG. 9B with the exception that the VFFS system 10′ ofFIG. 9D does not include a cutting mechanism (i.e., the finishingstation 26 of the VFFS system 10′ of FIG. 9D only includes the gussetingmechanism 26 a and the sealing mechanism 26 c). Because the VFFS system10′ of FIG. 9D does not include a cutting mechanism, the sheet ofmaterial S that is interfaced with the VFFS system 10′ may be pre-cut ina manner to include at least one first cut DC₁ and at least one secondcut DC₂. As shown in FIG. 9C, the pre-cuts DC₁, DC₂ formed in the sheetof material S may include a substantially triangular shape.

Referring to FIG. 9E, another exemplary implementation of the VFFSsystem 10′ including a gusseting mechanism 26 a defined by a firstgusseting disk 26 a ₁ and a second gusseting disk 26 a ₂ defining a pairof gusseting disk 26 a is described. The VFFS system 10′ of FIG. 9D issubstantially similar to the VFFS system 10′ of FIG. 9B with theexception that the VFFS system 10′ of FIG. 9D does not include a cuttingmechanism (i.e., the finishing station 26 of the VFFS system 10′ of FIG.9D only includes the gusseting mechanism 26 a and the sealing mechanism26 c). Because the VFFS system 10′ of FIG. 9D does not include a cuttingmechanism, the sheet of material S that is interfaced with the VFFSsystem 10′ may be pre-cut in a manner to include at least one first cutDC₁ and at least one second cut DC₂.

Referring to FIG. 14A, an exemplary method (see also, e.g., 300 at FIG.22) for utilizing a VFFS system 10″ is described. In someimplementations, the steps 301-305 of the method 300 are sequentiallycarried out in successive order.

An elongated sheet of material S is rotatably supported on the supportrod 12 at 301 and is arranged about the plurality of tensioners 14 inorder to keep the elongated sheet of material S taught as the elongatedsheet of material S is guided through the VFFS system 10″. The pluralityof tensioners 14 may be defined by at least, for example, a leadingtensioner 14 ₁ and a trailing tensioner 14 ₇. In some instances, theplurality of tensioners 14 may also include a plurality of intermediatetensioners 14 ₂-14 ₆ arranged between the leading tensioner 14 ₁ and thetrailing tensioner 14 ₇. The elongated sheet of material S is passedfrom the trailing tensioner 14 ₇ for subsequent guiding over the sheetguide 16 and toward the vertically arranged forming tube 18 and theproduct delivery cylinder 20.

The sheet guide 16 directs the elongated sheet of material S into thevertically arranged forming tube 18 that is arranged around the productdelivery cylinder 20. Once the elongated sheet of material S is directedinto the vertically-arranged forming tube 18, the vertically-arrangedforming tube 18 draws the left edge E_(L) and the right edge E_(R) ofthe elongated sheet of material S together in an overlappingconfiguration while also reconfiguring the spatial geometry of theelongated sheet of material S from a substantially planar shape (asseen, e.g., about the plurality of tensioners 14) to a substantiallycylindrical or tube shape about the vertically-arranged forming tube 18at 302. The pair of spaced-apart drive belts 22 is arranged in directcontact with the substantially cylindrical or tube-shaped elongatedsheet of material S for advancing the substantially cylindrical ortube-shaped elongated sheet of material S along the vertically arrangedforming tube 18 and away from a material depositing opening 28 of theproduct delivery cylinder 20.

As the substantially cylindrical or tube-shaped elongated sheet ofmaterial S is pulled downwardly by the pair of spaced-apart drive belts22, the overlapping configuration of the left edge E_(L) and the rightedge E_(R) of the elongated sheet of material S results in at least aportion of the first half of the vertically-sealable lip portion LV₁being arranged in an overlapped orientation with respect to at least aportion of the second half of the vertically-sealable lip portion LV₂.Once the first half of the vertically sealable lip portion LV₁ isoverlapped with the second half of the vertically sealable lip portionLV₂ the first half of the vertically sealable lip portion LV₁ is joinedto the second half of the vertically sealable lip portion LV₂ by thevertical sealer 24 at 303.

After the first half of the vertically-sealable lip portion LV₁ isjoined to the second half of the vertically-sealable lip portion LV₂ bythe vertical sealer 24, the substantially cylindrical or tube-shapedelongated sheet of material S is advanced away from the vertical sealer24 by the pair of spaced-apart drive belts 22 and toward the finishingstation 26. Referring to FIGS. 14B and 14C, the finishing station 26 mayinclude one or more mechanisms 26 a, 26 b, and 26 c for furtherspatially and physically manipulating the substantially cylindrical ortube-shaped elongated sheet of material S that will ultimately providethe substantially flat, rectangular-shaped footprint of the flat-bottomstand-up bag B. Some or all of the one or more mechanisms may beconnected to one or more actuators A. The one or more actuators A maycause the one or more mechanisms 26 a, 26 b, 26 c to be spatiallymanipulated relative to the sheet of material S in order to form theflat-bottom stand-up bag B. The one or more actuators A may be connectedto a computing resource C. The computing resource C may send one or moreperiodic actuating signals to the one or more actuators A for causingmovement of or actuating the one or more actuators A.

Referring to FIGS. 14B and 15A-15C, in some implementations, thefinishing station 26 includes a gusseting mechanism 26 a defined by afirst stationary gusseting rail 26 a ₁ and a second stationary gussetingrail 26 a ₂ defining a pair of stationary gusseting rails 26 a. Thefirst stationary gusseting rail 26 a ₁ is spaced apart from the secondstationary gusseting rail 26 a ₂ by a distance D, thereby forming a gapG therebetween.

With reference to FIGS. 14B, 15A, and 15B, the pair of spaced-apartdrive belts 22 advances the substantially cylindrical or tube-shapedelongated sheet of material S through the finishing station 26 such thatthe substantially cylindrical or tube-shaped elongated sheet of materialS is drawn through the gap G between the first stationary gusseting rail26 a ₁ and the second stationary gusseting rail 26 a ₂. With referenceto FIGS. 15B-15C, because a spacing between the left sidewall panelportion SP_(L) and the right sidewall panel portion SP_(R) of thesubstantially cylindrical or tube-shaped elongated sheet of material Sis defined by a geometry that is greater than the distance D between thefirst stationary gusseting rail 26 a ₁ and a second stationary gussetingrail 26 a ₂, the pair of stationary gusseting rails 26 a ₁, 26 a ₂shapes each of the left sidewall panel portion SP_(L) of thesubstantially cylindrical or tube-shaped elongated sheet of material Sand the right sidewall panel portion SP_(R) of the substantiallycylindrical or tube-shaped elongated sheet of material S to include agusseted tuck T at 304 as the pair of spaced-apart drive belts 22advances the substantially cylindrical or tube-shaped elongated sheet ofmaterial S through the finishing station 26.

Referring to FIG. 14C, in some instances, the gusseting mechanism 26 amay alternatively include a first gusseting disk 26 a ₁ and a secondgusseting disk 26 a ₂ that are spaced apart by a distance D, therebyforming a gap G therebetween. In some examples, the gusseting disks 26 a₁, 26 a ₂ may be spatially fixed in place. In other examples, eachgusseting disk 26 a ₁, 26 a ₂ may be permitted to rotate about an axisA-A extending through an axial center of each gusseting disk 26 a ₁, 26a ₂. The gusseting disks 26 a ₁, 26 a ₂ may function in a substantiallysimilar manner as described above with respect to the first stationarygusseting rail 26 a ₁ and a second stationary gusseting rail 26 a ₂(FIGS. 15A-15C). If the gusseting disks 26 a ₁, 26 a ₂ are permitted torotate about the axis A-A, the gusseting disks 26 a ₁, 26 a ₂ maypassively rotate about the axis A-A as the spaced-apart drive belts 22advance the substantially cylindrical or tube-shaped elongated sheet ofmaterial S through the finishing station 26.

Referring to FIGS. 16A and 16B, in some implementations, the finishingstation 26 further includes an integrated cutting and sealing mechanism26 b+26 c. After the substantially cylindrical or tube-shaped elongatedsheet of material S has been shaped to form the gusset tucks T asdescribed above, the pair of spaced-apart drive belts 22 advances thegusseted, substantially cylindrical or tube-shaped elongated sheet ofmaterial S through the finishing station 26 such that the gusseted,substantially cylindrical or tube-shaped elongated sheet of material Sis interfaced with the integrated cutting and sealing mechanism 26 b+26c. The integrated cutting and sealing mechanism 26 b+26 c simultaneouslyremoves a first portion DC₁′ and a second portion DC₂′ of the gusseted,substantially cylindrical or tube-shaped elongated sheet of material Sin order to form the gusseted, substantially cylindrical or tube-shapedelongated sheet of material S to include a first cut DC₁ and a secondcut DC₂ (as seen in FIGS. 16A-16B) while also sealing the gusseted,substantially cylindrical or tube-shaped elongated sheet of material S(as seen in FIG. 17) at 305.

The cutting component of the cutting and sealing mechanism 26 b+26C mayinclude, but is not limited to: one or more knives, one or morescissors, one or more punchers, one or more die-cutters, one or moreshears, one or more lasers, or the like. As seen in FIGS. 14B and 14C,the cutting and sealing mechanism 26 b+26 c may include a “K-shaped”sealing mechanism. Functionally, the sealing portion of the integratedcutting and sealing mechanism 26 b+26 c may spatially manipulate andseal the gusseted, substantially cylindrical or tube-shaped elongatedsheet of material S at 305 in a manner by: (1) folding the bottom edgeE_(B) (see, e.g., FIG. 16B) of the gusseted, substantially cylindricalor tube-shaped elongated sheet of material S such that the fronthorizontally-sealable lip portion LH_(F) overlaps with both of the firsthalf of the back horizontally-sealable lip portion LH_(B1) and thesecond half of the back horizontally-sealable lip portion LH_(B2); andthen (2) sealing the front horizontally-sealable lip portion LH_(F) toboth of the first half of the back horizontally-sealable lip portionLH_(B1) and the second half of the back horizontally-sealable lipportion LH_(B2) to thereby seal the plurality of horizontally-sealablelip portions LH and form the enclosed end wall EW.

Referring to FIG. 18, once the integrated cutting and sealing mechanism26 b+26 c of the finishing station 26 simultaneously cuts, folds andseals 305 the gusseted, substantially cylindrical or tube-shapedelongated sheet of material S to form the enclosed end wall EW asdescribed above, the VFFS system 10″ is then subsequently actuated forpassing foodstuff F (e.g., cereal, chips, popcorn, candy, nuts or thelike) through the material depositing opening 28 of the product deliverycylinder 20 and then through the vertically-arranged forming tube 18 forsubsequent arrival in a cavity formed by the sealed, folded, cut andgusseted, substantially cylindrical or tube-shaped elongated sheet ofmaterial S. The enclosed end wall EW prevents the foodstuff F fromescaping out of the cavity of the sealed, folded, cut, gusseted,substantially cylindrical, or tube-shaped elongated sheet of material Swhile the sealed, folded, cut and gusseted, substantially cylindrical ortube-shaped elongated sheet of material S is still interfaced with theVFFS system 10″.

Referring to FIGS. 14A and 19A-19D, the pair of spaced-apart drive belts22 may then advance the sealed, folded, cut and gusseted, substantiallycylindrical or tube-shaped elongated sheet of material S (including thefoodstuff F deposited therein), through the finishing station 26 suchthat the enclosed end wall EW of the sealed, folded, cut and gusseted,substantially cylindrical or tube-shaped elongated sheet of material S(including the foodstuff F deposited therein) is moved past theintegrated cutting and sealing mechanism 26 b+26 c. Movement of thesealed, folded, cut and gusseted, substantially cylindrical ortube-shaped elongated sheet of material S (including the foodstuff Fdeposited therein), may cease once the top edge E_(T) of the sealed,folded, cut and gusseted, substantially cylindrical or tube-shapedelongated sheet of material S (including the foodstuff F depositedtherein) is arranged proximate the integrated cutting and sealingmechanism 26 b+26 c. Then, the integrated cutting and sealing mechanism26 b+26 c may be actuated again for simultaneously sealing the top edgeE_(T) of the sealed, folded, cut and gusseted, substantially cylindricalor tube-shaped elongated sheet of material S (including the foodstuff Fdeposited therein) while also simultaneously forming an enclosed endwall EW of the next segment of the plurality of segments S_(P) reeledfrom the elongated sheet of material S. When the top edge E_(T) of thesealed, folded, cut and gusseted, substantially cylindrical ortube-shaped elongated sheet of material S (including the foodstuff Fdeposited therein) is sealed as described above, a cutter of theintegrated cutting and sealing mechanism 26 b+26 c severs the sealed,folded, cut and gusseted, substantially cylindrical or tube-shapedelongated sheet of material S (including the foodstuff F depositedtherein) along the top edge E_(T) to thereby provide the flat bottomstand-up bag B with the foodstuff F provided therein.

A number of implementations have been described. Nevertheless, it willbe understood that various modifications may be made without departingfrom the spirit and scope of the disclosure. Accordingly, otherimplementations are within the scope of the following claims. Forexample, the actions recited in the claims can be performed in adifferent order and still achieve desirable results.

What is claimed is:
 1. A vertical form fill and seal system comprising:a support rod that rotatably supports an elongated sheet of materialdefined by a plurality of material segments; a forming tube sized fordrawing a left edge and a right edge of said elongated sheet of materialtogether in an overlapping configuration to form said elongated sheet ofmaterial into a tube shape; a sealer sized for sealing said left edgeand said right edge of said elongated sheet of material to one anotherto form the tube shape; a gusseting mechanism sized for forming agusseted tuck in each of a left sidewall panel portion and a rightsidewall panel portion of said-tube shape to form a gusseted tube shape;a cutting mechanism that forms a first cut and a second cut in saidfirst segment of the gusseted tube shape, wherein the first cut removesa first portion of the elongated sheet of material from only half of thegusseted tuck in the left sidewall panel portion and the second cutremoves a second portion of the elongated sheet of material from onlyhalf of the gusseted tuck in the right sidewall panel portion within afirst segment of said plurality of material segments; and a sealing andfolding mechanism that folds and seals said first segment at said firstcut and at said second cut to provide an end wall of said first segmentwith a rectangular-shaped footprint.
 2. The system of claim 1, furthercomprising a cutter operable to sever said first segment from a secondsegment located downstream of said first segment.
 3. The system of claim1, wherein said cutting mechanism is disposed downstream from saidforming tube.
 4. The system of claim 1, wherein said first portion andsaid second portion include a triangular shape.
 5. The system of claim2, wherein said cutter and said sealing and folding mechanism form anintegrated mechanism.
 6. The system of claim 5, wherein said cutter andsaid sealing and folding mechanism cooperate to provide a sealed edge atsaid end wall comprising a pair of legs extending from a cross memberthat joins said pair of legs, wherein said legs extend from said crossmember at an obtuse angle and away from one another.